Method of producing polyarylene sulfide

ABSTRACT

The production method of the present invention includes a step of supplying an organic polar solvent, a sulfur source, and a dihalo aromatic compound as reaction raw materials to at least one of a plurality of reaction vessels mutually communicated via a gas phase; a step of removing at least a portion of the water present in the reaction vessels; and a step of performing a polymerization reaction. These steps are carried out in parallel, and the reaction mixture is sequentially moved between reaction vessels. At that time, the internal temperatures of the reaction vessels are all not less than 150° C.

TECHNICAL FIELD

The present invention relates to a method of producing polyarylenesulfide.

BACKGROUND ART

Polyarylene sulfide (hereinafter, also referred to as “PAS”),represented by polyphenylene sulfide (hereinafter, also referred to as“PPS”), is an engineering plastic having excellent heat resistance,chemical resistance, flame retardancy, mechanical strength, electricalcharacteristics, dimensional stability, and the like. PAS can be formedinto various molded products, films, sheets, fibers, and the like byordinary melt processing methods, such as extrusion molding, injectionmolding, and compression molding. For this reason, PAS has been widelyused in a wide range of technical fields, such as electrical devices,electronic devices, devices for automobiles, packaging materials, andthe like.

As a method of producing PAS, represented by PPS, the method disclosedin Patent Document 1 is generally used, and has been widely used forindustrial purposes in the related art. Specifically, a generally usedmethod includes heating an alkali metal sulfide, particularly an alkalimetal sulfide containing hydrated water, in a polar organic solvent toremove water contained in the alkali metal sulfide hydrate, and thenadding a dihalobenzene to perform heat polymerization.

Patent Documents 2 to 4 disclose a continuous polymerization apparatusof PAS in which pressure-resistant polymerization vessels are connectedin series and the reaction solution is transported among thepolymerization vessels by means of a pressure differential, and a methodof continuous polymerization of PAS using the same.

Furthermore, Patent Document 5 discloses a method of producing asulfur-containing polymer including (a) preparing a mixture containing asulfide and a solvent in a first reactor, and (b) reacting an aromaticdihalogen compound and the above sulfide in a second reactor to form asulfur-containing polymer.

Additionally, Patent Document 6 discloses a method of producingpolyphenylene sulfide by reacting an alkali metal sulfide and a dihaloaromatic compound in an organic amide solvent.

Furthermore, Patent Document 7 discloses a method of producingpolyarylene sulfide by reacting a sulfiding agent and a dihalogenatedaromatic compound in an organic polar solvent in the presence of analkali metal hydroxide.

CITATION LIST Patent Literature

Patent Document 1: JP S45-3368 T

Patent Document 2: U.S. Pat. No. 4,056,515 B specification

Patent Document 3: U.S. Pat. No. 4,060,520 B specification

Patent Document 4: U.S. Pat. No. 4,066,632 B specification

Patent Document 5: JP 2002-505361 T

Patent Document 6: JP H8-183858 T

Patent Document 7: WO 2011/024879

SUMMARY OF INVENTION Technical Problem

Producing PAS in a short time is generally considered to be difficult.This is because (i) the water content of the raw materials used forperforming polymerization in a short time is preferably low because PASpolymerization is a nucleophilic substitution reaction, but availablemonomer sulfur sources are generally hydrates and a step for reducingwater content is needed prior to the polymerization reaction, and (ii)in the polymerizing step, the sulfur source is present in a state whereit has reacted and bonded with water, but water is freed as the sulfursource is consumed through progression of polymerization, and thisinhibits the nucleophilic substitution reaction and retardspolymerization.

The PAS produced by the method of Patent Document 1 has low molecularweight and melt viscosity, and also needs a long time for water removal(dehydration) preceding polymerization. This lengthens PAS productiontime and adversely affects yield per unit space-time (space-time yield).

Patent Documents 2 to 4 disclose PAS continuous polymerizationapparatuses that use a plurality of polymerization vessels, and methodsof continuous polymerization of PAS using these polymerizationapparatuses. However, Patent Documents 2 to 4 are insufficient ingreatly reducing dehydration time.

Patent Document 5 discloses a technique of reacting a mixture obtainedby reacting a sulfur source and a solvent in a first reactor, withp-dichlorobenzene in a second reactor, and dehydrating the hydratedwater of the sulfur source during that reaction. The weight averagemolecular weight of the PAS obtained by the method of Patent Document 5is low. For this reason, further polymerization is required toproductize the PAS obtained by this method, thus making the equipmentcomplicated. Additionally, this method is insufficient in reducingpolymerization time and improving space-time yield.

Furthermore, the respective space-time yields of the polyphenylenesulfide according to Patent Document 6 and the polyarylene sulfideaccording to Patent Document 7 are low.

The present invention takes the above problems into consideration, andan object of the present invention is to provide a production method bywhich polyarylene sulfide (PAS) having excellent yield per unitspace-time (space-time yield) is easily obtained in a short time.

Solution to Problem

To solve the above problem, a method of producing polyarylene sulfide(PAS) according to one embodiment of the present invention (hereinafter,also referred to as “the present production method”) includes asupplying step of supplying an organic polar solvent, a sulfur source,and a dihalo aromatic compound as reaction raw materials to at least oneof a plurality of reaction vessels mutually communicated via a gasphase; a dehydrating step of removing at least a portion of waterpresent in the plurality of reaction vessels; and a polymerizing step ofperforming a polymerization reaction of the sulfur source and the dihaloaromatic compound in the organic polar solvent. The steps are carriedout in parallel and the reaction mixture is sequentially moved betweenthe reaction vessels. The internal temperatures of the plurality ofreaction vessels are all not less than 150° C.

Advantageous Effects of Invention

According to one aspect of the present invention, a production method isprovided by which PAS having excellent yield per unit space-time(space-time yield) is easily obtained in a short time.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial cross-sectional view of a PAS continuous productionapparatus according to Embodiment 1 of the present invention.

FIG. 2 is a partial cross-sectional view of a PAS continuous productionmethod according to Embodiment 2 of the present invention.

FIG. 3 is a partial cross-sectional view of a PAS continuous productionmethod according to Embodiment 3 of the present invention.

FIG. 4 is schematic view of the configuration of a PAS continuousproduction apparatus according to Embodiment 5 of the present invention.

DESCRIPTION OF EMBODIMENTS Embodiment 1

An embodiment of the present invention will be described in detailbelow.

Polyarylene Sulfide Continuous Production Apparatus

First, the configuration of a polyarylene sulfide (PAS) continuousproduction apparatus that can be used in the method of producing PASaccording to an embodiment of the present invention (hereinafter, alsoreferred to as “the present production method”) will be described basedon FIG. 1.

FIG. 1 is a partial cross-sectional view illustrating the configurationof a PAS continuous production apparatus that can be used in the methodof producing PAS according to the present embodiment.

To describe the apparatus in reference to FIG. 1, a PAS continuousproduction apparatus 100 includes a housing chamber 2 which houses aplurality of reaction vessels, namely reaction vessels 1 a, 1 b, and 1c. In the PAS continuous production apparatus 100, the housing chamber 2is installed at an incline so as to form an angle θ relative to thehorizontal plane H, as illustrated in FIG. 1. The shape of the housingchamber 2 is not particularly limited, and examples include a hollowround cylindrical shape or a hollow prismatic cylindrical shape, whereina side wall 3 a which abuts the reaction vessel 1 a and a side wall 3 bwhich abuts the reaction vessel 1 c serve as the base surfaces.

Lines that supply the reaction raw materials are connected to the sidewall 3 a of the housing chamber 2. Specifically, an organic polarsolvent supply line 4, which supplies an organic polar solvent to thehousing chamber 2, a sulfur source supply line 5, which supplies atleast one type of sulfur source selected from the group consisting ofalkali metal sulfides, alkali metal hydrosulfides, and hydrogen sulfideto the housing chamber 2, and a dihalo aromatic compound supply line 6,which supplies a dihalo aromatic compound to the housing chamber 2, areeach connected to the side wall 3 a of the housing chamber 2. Note thatan alkali metal hydroxide supply line (not illustrated), which suppliesan alkali metal hydroxide to the housing chamber 2, or a water supplyline (not illustrated), which supplies water, may also be connected asnecessary to the side wall 3 a.

The reaction raw materials of organic polar solvent, sulfur source, anddihalo aromatic compound, and other optionally used reaction rawmaterials may also be supplied to the liquid phase of the reactionvessel 1 a via a gas phase or may be supplied directly to the liquidphase of the reaction vessel 1 a. Note that in the presentspecification, a raw material means a raw material used in thepolymerization reaction of the method of producing PAS.

A reaction mixture recovery line 7 for recovering the reaction mixturefrom the housing chamber 2 is connected to the side wall 3 b of thehousing chamber 2.

The reaction vessel 1 a and the reaction vessel 1 b are separated by apartition 8 a, and the reaction vessel 1 b and the reaction vessel 1 care separated by a partition 8 b. The reaction vessel 1 a, the reactionvessel 1 b, and the reaction vessel 1 c are mutually communicated via agas phase in the housing chamber 2. As a result, the pressure of the gasphase in the housing chamber 2 is uniform. The effect obtained bycommunicating the reaction vessels in this manner will be describedbelow.

Since the housing chamber 2 is installed at an incline so as to form anangle θ relative to the horizontal plane H as illustrated in FIG. 1, themaximum liquid surface level of liquid that can be held decreases inorder from reaction vessel 1 a to 1 b to 1 c. The reaction vessel 1 a,the reaction vessel 1 b, and the reaction vessel 1 c are connected inseries in the above order. The effect obtained by connecting thereaction vessels in this manner will be described below. Note that ineach of the reaction vessels except for the reaction vessel 1 a which isfurthest upstream in the movement direction of the reaction mixture, theminimum height of the partition on the upstream side in the movementdirection of the reaction mixture is higher than the maximum liquidsurface level of that reaction vessel. Specifically, in the reactionvessel 1 b, the minimum height of the partition 8 a on the upstream sidein the movement direction of the reaction mixture is higher than themaximum liquid surface level of the reaction vessel 1 b. In the reactionvessel 1 c, the minimum height of the partition 8 b on the upstream sidein the movement direction of the reaction mixture is higher than themaximum liquid surface level of the reaction vessel 1 c. As a result,reverse flow from the reaction vessel 1 b to the reaction vessel 1 a andreverse flow from the reaction vessel 1 c to the reaction vessel 1 b areprevented. The reaction vessel 1 a, the reaction vessel 1 b, and thereaction vessel 1 c can hold a reaction mixture 9 a, a reaction mixture9 b, and a reaction mixture 9 c, respectively.

Due to the reaction vessels 1 a to 1 c being connected serially in theabove order, the reaction mixture moves by gravity and according to thedifference in liquid surface levels. For this reason, according to thepresent embodiment, there is no need to provide a separate means formoving the reaction mixture to the subsequent reaction vessel.

A stirring blade 10 a, which stirs the reaction mixture 9 a in thereaction vessel 1 a, a stirring blade 10 b, which stirs the reactionmixture 9 b in the reaction vessel 1 b, and a stirring blade 10 c, whichstirs the reaction mixture 9 c in the reaction vessel 1 c, are installedon the same stirring shaft 11 in the housing chamber 2. The stirringshaft 11 is installed to penetrate through the side wall 3 a fromoutside the housing chamber 2 and reaches the side wall 3 b. A rotationdrive apparatus 12 which rotates the stirring shaft 11 is installed onthe end of the stirring shaft 11 nearest the side wall 3 a.

One end of an exhaust line 13 is connected near the side wall 3 a of thehousing chamber 2. A dehydrating unit 14, which performs dehydrationfrom the gas phase in the housing chamber 2, is connected to the otherend of the exhaust line 13. The dehydrating unit 14 communicates withthe gas phase in the housing chamber 2 via the exhaust line 13. One endof an organic polar solvent recovery line 15 is connected to one end(for example, the lower part) of the dehydrating unit 14. One end of avapor recovery line 16 is connected to the other end (for example, theupper part) of the dehydrating unit 14. A gas-liquid separating unit 17is connected to the other end of the vapor recovery line 16. A reactionraw material separating and recovering unit 19 is connected to the otherend of a gas recovery line 18 which branches off from one end (forexample, the upper part) of the gas-liquid separating unit 17. A wastegas line 20 and a reaction raw material resupply line 21 branch off fromthe reaction raw material separating and recovering unit 19, and areaction raw material resupply unit 22 is connected to the reaction rawmaterial resupply line 21. The reaction raw material resupply unit 22resupplies at least a portion of the reaction materials separated andrecovered in the reaction raw material separating and recovering unit 19to at least some of the reaction vessels 1 a to 1 c. On the other hand,a reaction raw material separating and recovering unit 24 is connectedto the other end of a liquid recovery line 23 which branches off fromthe other end (for example, the lower part) of the gas-liquid separatingunit 17. A waste water line 25 and a reaction raw material resupply line26 branch off from the reaction raw material separating and recoveringunit 24, and a reaction raw material resupply unit 27 is connected tothe reaction raw material resupply line 26. The reaction raw materialresupply unit 27 resupplies at least a portion of the reaction materialsseparated and recovered in the reaction raw material separating andrecovering unit 24 to at least some of the reaction vessels 1 a to 1 c.At least a portion of the reaction raw materials may be supplied to theliquid phase of at least some of the reaction vessels 1 a to 1 c via thegas phase, or may be supplied directly to the liquid phase of at leastsome of the reaction vessels 1 a to 1 c.

A gas feeding unit 28 is connected via a gas feeding line 29 to the sidewall 3 b of the housing chamber 2. The gas feeding unit 28 communicateswith the gas phase in the housing chamber 2 and feeds an inert gas tothat gas phase from the downstream side toward the upstream side of themovement direction of the reaction mixture, specifically, from thereaction vessel 1 c toward the reaction vessel 1 a. The inert gas is notparticularly limited, and examples include rare gases such as argon, andnitrogen.

Next, the method of producing PAS and the operation of the PAScontinuous production apparatus according to the present embodiment willbe described together based on FIG. 1.

Method of Producing PAS

The present production method includes a supplying step of supplying anorganic polar solvent, a sulfur source, and a dihalo aromatic compoundas reaction raw materials to at least one of a plurality of reactionvessels mutually communicated via a gas phase; a dehydrating step ofremoving at least a portion of water present in the plurality ofreaction vessels; and a polymerizing step of performing a polymerizationreaction of the sulfur source and the dihalo aromatic compound in theorganic polar solvent. The steps are carried out in parallel and thereaction mixture is sequentially moved between the reaction vessels. Theinternal temperatures of the plurality of reaction vessels are all notless than 150° C.

To specifically describe the present production method, in the supplyingstep, each of the reaction raw materials, namely an organic polarsolvent, at least one type of sulfur source selected from the groupconsisting of alkali metal sulfides, alkali metal hydrosulfides, andhydrogen sulfide, and a dihalo aromatic compound, are supplied to thehousing chamber 2 via the organic polar solvent supply line 4, thesulfur source supply line 5, and the dihalo aromatic compound supplyline 6, respectively. Note that the reaction raw materials may besupplied to the housing chamber 2 after a portion or all of the reactionraw materials have been premixed. For example, a mixture of the organicpolar solvent and the dihalo aromatic compound or a mixture of theorganic polar solvent and the sulfur source may be prepared in advance,and this mixture may be supplied to the housing chamber 2. Furthermore,the mixture may be supplied after being heated, after being reactedwhile heating, or after being reacted without heating. In this case, forexample, a mixture supply line (not illustrated) may be connected to theside wall 3 a and the above mixture may be supplied to the housingchamber 2 via this mixture supply line instead of the organic polarsolvent supply line 4 and dihalo aromatic compound supply line 6.

The present embodiment is a case where the sulfur source is continuouslysupplied. In this case, the total supply quantity in terms of sulfuratoms is preferably not less than 0.1 mol/hr, more preferably not lessthan 1 mol/hr, even more preferably not less than 10 mol/hr, andparticularly preferably 100 mol/hr. In the case where the sulfur sourceis supplied in a single batch or divided into multiple batches, thetotal supply quantity in terms of sulfur atoms is preferably not lessthan 0.1 Kmol, more preferably not less than 0.2 Kmol, even morepreferably not less than 0.3 Kmol.

In the polymerizing step, first, the supplied organic polar solvent,sulfur source, dihalo aromatic compound, and the like are mixed in thereaction vessel 1 a, and the reaction mixture 9 a is formed by apolymerization reaction of the sulfur source and the dihalo aromaticcompound in the organic polar solvent.

In the present embodiment, the time from the start of the supplying stepto completion of the polymerizing step is preferably not greater than 7hours, more preferably not greater than 6 hours, and even morepreferably not greater than 5 hours. Note that in the case of continuousprocessing, the average residence time from the start of supply tocompletion of polymerization is considered to be the time from the startof the supplying step to completion of the polymerizing step.Furthermore, in the case where continuous processing and batchprocessing are combined, it is the time needed to process the quantityof a single batch from the start of the supplying step to completion ofthe polymerizing step.

In a more preferred embodiment, the total supply quantity of the sulfursource in terms of sulfur atoms is preferably not less than 0.1 mol/hr,more preferably not less than 1 mol/hr, even more preferably not lessthan 10 mol/hr, and particularly preferably not less than 100 mol/hr,and also, the time from the start of the supplying step to completion ofthe polymerizing step is preferably not greater than 7 hours, morepreferably not greater than 6 hours, and even more preferably notgreater than 5 hours.

Those typically used in the production of PAS may be used as the organicpolar solvent, the at least one type of sulfur source selected from thegroup consisting of alkali metal sulfides, alkali metal hydrosulfides,and hydrogen sulfide, and the dihalo aromatic compound.

Examples of the organic polar solvent include organic amide solvents.Examples of the organic amide solvents include amide compounds, such asN,N-dimethylformamide and N,N-dimethylacetamide; N-alkylcaprolactamcompounds, such as N-methyl-ε-caprolactam; N-alkylpyrrolidone compoundsor N-cycloalkylpyrrolidone compounds, such as N-methyl-2-pyrrolidone(NMP) and N-cyclohexyl-2-pyrrolidone; N,N-dialkylimidazolidinonecompounds, such as 1,3-dialkyl-2-imidazolidinone; tetraalkyl ureacompounds, such as tetramethyl urea; and hexaalkylphosphate triamidecompounds, such as hexamethyl phosphate triamide.

Examples of the sulfur source include alkali metal sulfides, alkalimetal hydrosulfides, and hydrogen sulfide. Alkali metal sulfides andalkali metal hydrosulfides are preferred as the sulfur source from theperspective that they are easy to handle and inexpensive. The sulfursource may be handled in the form of an aqueous slurry or aqueoussolution, and is preferably in the form of an aqueous solution from theperspective of ease of handling in measurement, transport, and the like.

Examples of the alkali metal sulfides include lithium sulfide, sodiumsulfide, potassium sulfide, rubidium sulfide, and cesium sulfide.

Examples of the alkali metal hydrosulfides include lithium hydrosulfide,sodium hydrosulfide, potassium hydrosulfide, rubidium hydrosulfide, andcesium hydrosulfide.

When an alkali metal hydrosulfide or alkali metal sulfide is used as thesulfur source, an alkali metal hydroxide is used in combination.Examples of the alkali metal hydroxides include lithium hydroxide,sodium hydroxide, potassium hydroxide, rubidium hydroxide, cesiumhydroxide, and mixtures of two or more of these. Of these, sodiumhydroxide and lithium hydroxide are preferred from the perspective ofbeing available at low cost for industrial purposes. Furthermore, anaqueous solution or slurry is preferred from the perspective of handlingand the like.

When any of an alkali metal sulfide, an alkali metal hydrosulfide, andhydrogen sulfide are used in a mixture, then naturally, these mixturesserve as the sulfur source.

Examples of the dihalo aromatic compounds include o-dihalobenzenes,m-dihalobenzenes, p-dihalobenzenes, dihalotoluenes, dihalonaphthalenes,methoxy-dihalobenzenes, dihalobiphenyls, dihalobenzoic acids,dihalodiphenyl ethers, dihalodiphenyl sulfones, dihalodiphenylsulfoxides, and dihalodiphenyl ketones. The halogen atoms in the dihaloaromatic compound each refers to an atom of fluorine, chlorine, bromine,or iodine. The two halogen atoms in the dihalo aromatic compound may bethe same or different. Of these, p-dihalobenzene, m-dihalobenzene or amixture of these two is preferred, p-dihalobenzene is more preferred,and p-dichlorobenzene (pDCB) is particularly preferred.

The alkali metal sulfide, the alkali metal hydrosulfide, and the dihaloaromatic compound respectively may be used alone, or may be used bymixing two or more types as long as the combination can produce PAS.

Note that water may be added to at least one of the reaction vessels 1 ato 1 c. The quantity of water added at that time may be, for example,approximately from 0.1 to 10 moles per mole of sulfur source, withoutparticular limitation.

The above polymerization reaction is preferably carried out at 170° C.to 290° C. until the conversion ratio of the dihalo aromatic compound isnot less than 50%.

The conversion ratio of the dihalo aromatic compound is preferably from50 to 100%, more preferably from 60 to 100%, even more preferably from65 to 100%, and particularly preferably from 70 to 100%. The conversionratio of the dihalo aromatic compound can be calculated by determiningthe amount of the dihalo aromatic compound remaining in the reactionmixture by gas chromatography and then performing a calculation based onthe remaining amount of the dihalo aromatic compound, the charged amountof the dihalo aromatic compound, and the charged amount of the sulfursource.

In the present production method, in the dehydrating step, at least aportion of the water in the housing chamber 2 is removed from thehousing chamber 2 via the gas phase in the housing chamber 2 by theaction of the dehydrating unit 14 (described in detail later) whichlinks to the exhaust line 13. As a result, at least a portion of thewater present in the reaction vessels 1 a to 1 c is removed. Examples ofthe water in the housing chamber 2 include water supplied to the housingchamber 2 and water generated by the polymerization reaction. When thegas phase in the housing chamber 2 contains a large amount of moisture,the pressure inside the housing chamber 2 tends to be high because thevapor pressure of water is high. For this reason, the housing chamber 2needs to be pressure-resistant, which makes it difficult to save onresources and reduce equipment costs. Dehydration is carried out by thedehydrating unit 14 and the pressure inside the housing chamber 2 isreduced. Such a configuration effectively realizes resource savings andreduced equipment costs.

The pressure inside the housing chamber 2 which is the reaction systemis, for example, preferably from 0.01 MPa to 0.8 MPa, more preferablyfrom 0.02 MPa to 0.65 MPa, even more preferably from 0.03 MPa to 0.39MPa, and particularly preferably from 0.04 MPa to 0.37 MPa.

As described above, the reaction vessels 1 a to 1 c are mutuallycommunicated via a gas phase in the housing chamber 2, and the pressureof the gas phase in the housing chamber 2 is uniform. For this reason,water is removed equally from all of the reaction vessels 1 a to 1 c bythe dehydrating unit 14 in the dehydrating step. Thus, the quantity ofwater in the reaction mixture becomes smaller in the direction from thereaction vessel 1 a to the reaction vessel 1 c, specifically, from theupstream side to the downstream side of the movement direction of thereaction mixture. As a result, reaction inhibition due to water issuppressed and the polymerization reaction is accelerated. Furthermore,since the boiling point of the reaction mixture rises, polymerization athigh temperatures becomes possible and the polymerization reaction canbe further accelerated. Additionally, through the above acceleration ofthe polymerization reaction, the temperature of the reaction mixturetends to rise and the polymerization reaction tends to be furtheraccelerated.

As described above, by arranging the parts as described above andperforming a continuous reaction in the PAS continuous productionapparatus 100, the temperature of the reaction vessels 1 a to 1 c can beincreased from the upstream side toward the downstream side of themovement direction. In other words, the internal temperatures of thereaction vessels 1 a to 1 c can be set so as to increase from theupstream side toward the downstream side of the movement direction ofthe reaction mixture.

Furthermore, as described above, the reaction vessels 1 a to 1 c areconnected in descending order of maximum liquid surface level of liquidthat each reaction vessel can hold. As a result, in the movement processof the reaction mixture, the reaction mixture can be sequentially movedutilizing the difference in maximum liquid surface levels. Morespecifically, when the surface level of the reaction mixture 9 a and thereaction mixture 9 b exceed the maximum liquid surface level, thereaction mixtures can exceed the partition 8 a and the partition 8 b,respectively. Note that the shape of the partitions 8 a and 8 b may beany shape without particular limitation as long as there is no hindranceto the mutual communication of the reaction vessel 1 a, the reactionvessel 1 b, and the reaction vessel 1 c via a gas phase in the housingchamber 2. Furthermore, it may be configured such that openings such asthrough holes or slits (not illustrated) are provided in the partitionsand the reaction solution moves via these openings.

In the present embodiment, the internal temperatures of the reactionvessels 1 a, 1 b, and 1 c are all not less than 150° C. Preferably, thesupply reaction vessel to which the reaction raw materials are supplied,specifically, the reaction vessel 1 a is preferably not less than 160°C., more preferably not less than 170° C., and even more preferably notless than 180° C.

Furthermore, the respective internal temperatures of the reactionvessels other than the supply reaction vessel, specifically, thereaction vessels 1 b and 1 c are preferably not less than 200° C., morepreferably not less than 210° C., and even more preferably not less than220° C. Additionally, the internal temperatures of one or more reactionvessels other than the supply reaction vessel are preferably not lessthan 245° C., more preferably not less than 250° C., and even morepreferably not less than 255° C. In the present embodiment, thedifference in internal temperatures of two mutually adjacent reactionvessels is preferably not less than 2° C., more preferably not less than3° C., and even more preferably not less than 5° C. By setting theinternal temperatures of the reaction vessels 1 a to 1 c in this manner,the above dehydrating step can be carried out mainly in the supplyreaction vessel, specifically, in the reaction vessel 1 a, and thepolymerization reaction can be carried out mainly in the reaction vesselprovided on the downstream side of the movement direction of thereaction mixture relative to the reaction vessel 1 a, specifically, inthe reaction vessel 1 b. As a result, the polymerization reaction can becarried out more efficiently.

In the present embodiment, an inert gas be preferably fed in by the gasfeeding unit 28 to the gas phase in the housing chamber 2 from thedownstream side toward the upstream side of the movement direction ofthe reaction mixture, specifically, from the reaction vessel 1 c towardthe reaction vessel 1 a. As described above, in order to maintain astate in which the quantity of water in the reaction mixture becomessmaller in the direction from the upstream side toward the downstreamside of the movement direction of the reaction mixture, it is preferredthat moisture evaporating from the reaction mixture flow to thedownstream side so that it does not condense on the reaction mixture. Byfeeding an inert gas into the gas phase as described above via the gasfeeding unit 28, water vapor can be effectively prevented fromcondensing on the reaction mixture by flowing to the downstream side.

The flow rate of the inert gas is not particularly limited as long asthe water vapor is not hindered from flowing to the downstream side. Forexample, when the housing chamber 2 has a hollow round cylindrical shapeof inner radius r in which the side wall 3 a and the side wall 3 b serveas the base surfaces, when the flow rate of the inert gas is taken as uand the volumetric flow rate of the inert gas is taken as F, the flowrate is expressed as u=F/(πr²). Here, in a case where the water vapor isless likely to flow to the downstream side, Taylor dispersion forms.Specifically, considering that conditions change from moleculardiffusion control to convection diffusion control, the condition underwhich Taylor dispersion holds is r·u>>D (where D is the diffusioncoefficient of water vapor). From the above facts, examples of the flowrate of the inert gas include values within a range such that F>>D·πr,more specifically F>10D·πr, preferably F>25D·πr, and more preferablyF>50D·πr. Note that when the housing chamber 2 has a hollow roundcylindrical shape in which the side wall 3 a and the side wall 3 b serveas the base surfaces and the cross-section perpendicular to the movementdirection of the reaction mixture may have any shape, the above equationcan be applied using the representative length in the directionperpendicular to the movement direction of the reaction mixture, forexample, the equivalent circular radius of the cross-section having anyshape, as r.

The stirring shaft 11 rotates by means of the rotation drive apparatus12, and the stirring blades 10 a to 10 c installed on the stirring shaft11 rotate accordingly around the stirring shaft 11 and mix the reactionmixtures 9 a to 9 c. The stirring blades 10 a to 10 c are installed onthe same stirring shaft 11. For this reason, all of the stirring blades10 a to 10 c are rotated under the same conditions simply by rotatingthe stirring shaft 11 by means of the rotation drive apparatus 12, anduniform mixing can be established with high efficiency.

As the above polymerization reaction proceeds, alkali metal halides suchas NaCl precipitate out and accumulate in the reaction vessels 1 a to 1c. As a result, the effective volume for sufficiently driving thepolymerization reaction forward in the reaction vessels 1 a to 1 cdecreases and productivity tends to drop. This results in excessivemaintenance work to remove the accumulated alkali metal halides. Bymixing the reaction mixtures 9 a to 9 c using the stirring blades 10 ato 10 c, the alkali metal halides disperse in the reaction mixtures 9 ato 9 c and move to the downstream side, and thereby easily discharged tooutside the housing chamber 2. On the other hand, in a case where mixingis too vigorous, the reaction mixture flows over one or both of thepartition 8 a and partition 8 b, needlessly moving from the reactionvessel on the upstream side and is immixed into the reaction vessel onthe downstream side.

The shape, number, rotational speed, and the like of the stirring bladesare preferably adjusted as appropriate so as to promote dispersion ofalkali metal halides and avoid needless immixing of the reactionmixtures between the reaction vessels 1 a to 1 c. Examples of therotational speed of the stirring blades include conditions under whichalkali metal halides do not settle, and more specifically, a rotationalspeed at which the stirring velocity by the stirring blades is not lessthan the particle suspension limit stirring speed. From the perspectiveof easily preventing the reaction mixture from flowing over one or bothof the partition 8 a and partition 8 b, the upper limit of the tip speedof the stirring blades is preferably such that the rotational speed ofthe stirring blades is not greater than 60 rpm, and more preferably notgreater than 20.5 rpm. Furthermore, the rotation route and the like ofthe stirring blades is also preferably adjusted as appropriate so thatstirring is sufficient. For example, the stirring blades preferably atleast pass through a portion that is deeper than the average depth ofeach reaction vessel 1 a to 1 c. In particular, it is preferable toreduce the sizes of the gap between the stirring blade 10 a and thebottom portion of the reaction vessel 1 a, the gap between the stirringblade 10 a and the partition 8 a, the gap between the stirring blade 10b and the bottom portion of the reaction vessel 1 b, the gap between thestirring blade 10 b and the partition 8 b, the gap between the stirringblade 10 c and the bottom portion of the reaction vessel 1 c, and thegap between the stirring blade 10 c and the side wall 3 b, so thatstirring is sufficient and alkali metal halides do not accumulate nearthe deepest parts of each reaction vessel 1 a to 1 c.

Exhaust gas from the housing chamber 2 is supplied to the dehydratingunit 14 via the exhaust line 13. The dehydrating unit 14 acts as, forexample, a distillation column, wherein a liquid containing a maincomponent of organic polar solvent is recovered from one end (forexample, the lower part), and vapor containing the sulfur source, thedihalo aromatic compound, and water is recovered from the other end (forexample, the upper part).

The organic polar solvent recovered from the dehydrating unit 14 goesthrough purification and the like as necessary, and may be againsupplied to the housing chamber 2 as a reaction raw material of thepolymerization reaction. At that time, the recovered organic polarsolvent may be supplied to the housing chamber 2 via the organic polarsolvent supply line 4 or via an organic polar solvent supply line otherthan the organic polar solvent supply line 4. The supply destination ofthe recovered organic polar solvent may be any one of the reactionvessels 1 a to 1 c or a combination of two or more thereof.

The vapor recovered from the other end of the dehydrating unit 14 issupplied to the gas-liquid separating unit 17 via the vapor recoveryline 16. The gas-liquid separating unit 17 acts as, for example, adistillation column, wherein gas containing the sulfur source isrecovered from one end (for example, the upper part), and liquidcontaining the dihalo aromatic compound and water is recovered from theother end (for example, the lower part).

The gas recovered from the one end of the gas-liquid separating unit 17is supplied to the reaction raw material separating and recovering unit19 via the gas recovery line 18. In the reaction raw material separatingand recovering unit 19, the sulfur source is separated and recoveredfrom the gas and fed to the reaction raw material resupply line 21 viathe reaction raw material resupply unit 22. On the other hand, theremaining gas is disposed of as waste gas via the waste gas line 20.

At least a portion of the sulfur source separated and recovered by thereaction raw material separating and recovering unit 19 is preferablyresupplied to at least some of the reaction vessels 1 a to 1 c by thereaction raw material resupply unit 22. At that time, the separated andrecovered sulfur source may be resupplied to the reaction vessel 1 a viathe sulfur source supply line 5, or via a sulfur source supply lineother than the sulfur source supply line 5. By resupplying at least aportion of the sulfur source, the sulfur source can be effectivelyutilized and resource savings can be achieved.

The liquid recovered from the gas-liquid separating unit 17 is suppliedto the reaction raw material separating and recovering unit 24 via theliquid recovery line 23. In the reaction raw material separating andrecovering unit 24, the dihalo aromatic compound is separated andrecovered from the liquid and fed to the reaction raw material resupplyline 26 via the reaction raw material resupply unit 27. On the otherhand, the remaining liquid is disposed of as waste water via the wastewater line 25.

For this reason, at least a portion of the dihalo aromatic compoundseparated and recovered by the reaction raw material separating andrecovering unit 24 is preferably resupplied to at least some of thereaction vessels 1 a to 1 c by the reaction raw material resupply unit27. At that time, the separated and recovered dihalo aromatic compoundmay be resupplied to the reaction vessel 1 a via the dihalo aromaticcompound supply line 6, or via a dihalo aromatic compound supply lineother than the dihalo aromatic compound supply line 6. By resupplying atleast a portion of the dihalo aromatic compound, the dihalo aromaticcompound can be effectively utilized and resource savings can beachieved.

Furthermore, in driving the PAS continuous production apparatus 100, thereaction mixture moves utilizing gravity and the difference in maximumliquid surface levels, and a large amount of energy is not needed. Thus,the PAS continuous production apparatus 100 can easily achieve resourcesavings, energy savings, and reduced equipment costs.

The lower limit of weight average molecular weight (Mw) according to gelpermeation chromatography (GPC) of the PAS ultimately obtained by thepresent production method is not less than 8000, preferably not lessthan 10000, even more preferably not less than 13000, and particularlypreferably not less than 15000. It is also possible to obtain PAS havinga high molecular weight of 20000 or greater. The upper limit is notgreater than 200000, preferably not greater than 100000, and morepreferably not greater than 70000.

Furthermore, the space-time yield of the PAS ultimately obtained by thepresent production method is preferably not less than 14 g/hr·L, morepreferably not less than 14.5 g/hr·L, even more preferably not less than15 g/hr·L, and particularly preferably not less than 16 g/hr·L.

Thus, according to the present production method, complex control or thelike is unnecessary and PAS production is easy because the reaction rawmaterials can be supplied to just at least one of a plurality ofreaction vessels that are mutually communicated via a gas phase.

In the present embodiment, the method may further include a step ofincreasing the weight average molecular weight of the PAS obtained bythe polymerizing step. The weight average molecular weight of the PASmay be increased by, for example, using a polymerization aid in thepolymerization reaction. Specific examples of the polymerization aidinclude organic metal carboxylates, organic metal sulfonates, lithiumhalides, alkali metal sulfates, alkali earth metal oxides, alkali metalphosphates, and alkali earth metal phosphates. These can be used aloneor as a combination of two or more types. Above all, an organic metalcarboxylate or lithium halide is preferably used. More specific examplesinclude lithium acetate, sodium acetate, potassium acetate, sodiumpropionate, lithium benzoate, sodium benzoate, sodium phenyl acetate,sodium p-tolulate, and lithium chloride. Above all, lithium acetate orsodium acetate is preferably used, and sodium acetate is more preferablyused because it is inexpensive.

These polymerization aids may be used alone or may be used by mixing twoor more types as long as the combination can produce PAS.

In the present embodiment, when the total quantity of water contained inthe reaction raw materials is taken as 100 mass %, the quantity of watercontained in the above supply reaction vessel, specifically, thereaction vessel 1 a is preferably not less than 5 mass % and not greaterthan 99 mass %, more preferably not less than 6 mass % and not greaterthan 90 mass %, and even more preferably not less than 7 mass % and notgreater than 80 mass %. It is preferred that the quantity of watercontained in the supply reaction vessel be within this range because thequantity of water to be dehydrated is reduced in the polymerizing step.

Furthermore, the quantity of water contained in the above adjacentreaction vessel adjacent to the supply reaction vessel on the downstreamside, specifically, the reaction vessel 1 b is preferably not less than5 mass % and not greater than 50 mass %, more preferably not less than 6mass % and not greater than 40 mass %, and even more preferably not lessthan 7 mass % and not greater than 30 mass %. It is preferred that thequantity of water contained in the adjacent reaction vessel be withinthis range because the quantity of water to be dehydrated is reduced inthe polymerizing step.

A method of producing PAS using a certain apparatus was described in thepresent embodiment, but the production method according to the presentinvention may further include other steps as long as the method at leastinvolves a plurality of reaction vessels mutually communicated via a gasphase and includes the above supplying step, dehydrating step, andpolymerizing step, and these steps are carried out in parallel and thereaction mixture moves sequentially between the reaction vessels, andthe internal temperatures of the plurality of reaction vessels are allnot less than 150° C.

Furthermore, in the present embodiment, reaction vessels having acertain shape are used, but the shape of the reaction vessels is notparticularly limited.

Additionally, in the present embodiment, the number of reaction vesselsis not particularly limited. Furthermore, the reaction vessels do notnecessarily have to be connected in series as illustrated in FIG. 1.Thus, some of the plurality of reaction vessels may be lined up inparallel.

Additionally, for at least one pair of adjacent reaction vessels amongthe plurality of reaction vessels, the reaction vessel with a highermaximum liquid surface level of liquid that can be held in each reactionvessel is preferably located on the upstream side of the movementdirection of the reaction mixture, and the reaction mixture ispreferably moved utilizing the difference in maximum liquid surfacelevel. By doing so, resource savings, energy savings, and reducedequipment costs can be achieved because the reaction mixture movesutilizing gravity in at least one pair of reaction vessels.

Additionally, in the present embodiment, the feeding step of feeding inthe above inert gas is preferably carried out in parallel with each ofthe above steps. Furthermore, a separating and recovering step ofseparating and recovering a portion of the reaction raw materials asdescribed above and a resupplying step of supplying at least a portionof the reaction raw materials to at least one of the reaction vesselsare preferably further carried out in parallel with each of the abovesteps.

Additionally, in the present embodiment, a configuration in which thereaction raw materials are supplied to the reaction vessel 1 a wasdescribed, but the reaction vessel to which the reaction raw materialsare supplied is not specific.

Embodiment 2

Next, another embodiment of the present invention will be described indetail.

FIG. 2 is a partial cross-sectional view of another PAS continuousproduction apparatus used in the present production method. The methodof producing PAS and the configuration and operation of the PAScontinuous production apparatus according to the present embodiment willbe described below based on FIG. 2. Note that components having the samefunction as components described in Embodiment 1 are assigned the samereference signs and their descriptions are omitted.

In the present embodiment, a PAS continuous production apparatus 200used in the present production method is the same as the PAS continuousproduction apparatus 100 according to Embodiment 1 except that thehousing chamber 2 is placed horizontally, the dimensions of thepartition 8 a and the dimensions of the partition wall 8 b differ, andthe connection position of the reaction mixture recovery line 7 on theside wall 3 b differs.

The PAS continuous production apparatus 200 operates in the same manneras the PAS continuous production apparatus 100 described in Embodiment 1(see FIG. 1) except that when the base surface areas of the reactionvessels 1 a to 1 c are equal, as illustrated in FIG. 2, the quantity ofreaction mixture that can be held decreases in order from reactionvessel 1 a to 1 b to 1 c.

In the PAS continuous production apparatus 200, unlike the PAScontinuous production apparatus 100, the depths of the reaction vessels1 a to 1 c are substantially constant depending on location. Thus, it isparticularly preferred that mixing by the stirring blades 10 a to 10 cbe sufficient because alkali metal halides generated by thepolymerization reaction readily accumulate on the entire bottom surfacesof the reaction vessels 1 a to 1 c. To ensure sufficient stirring by thestirring blades 10 a to 10 c so that alkali metal halides do notaccumulate, the width of the stirring blades 10 a to 10 c is preferablywide, for example, not less than 50%, preferably not less than 60%, morepreferably not less than 70%, and even more preferably not less than 80%of the width of the reaction vessels 1 a to 1 c. Furthermore, some orall of the stirring blades 10 a to 10 c are preferably positioned in thecenter of each reaction vessel from the perspective that a largedeviation in mixing does not readily occur, and so forth.

In the present invention, a case where the stirring shaft 11 in theabove Embodiments 1 and 2 is single-screw is illustrated, but it may bemulti-screw such as a twin-screw or triple-screw.

Embodiment 3

Next, yet another embodiment of the present invention will be describedin detail.

FIG. 3 is a partial cross-sectional view of another PAS continuousproduction apparatus used in the present production method. Theconfiguration and operation of the present embodiment will be describedbelow based on FIG. 3.

To describe the present embodiment in reference to FIG. 3, a PAScontinuous production apparatus 300 differs from the above embodimentsin that the separation means that separate the reaction vessels in thehousing chamber 2 are divider plates having a rotating center.

In the present embodiment, the reaction vessel 1 a and the reactionvessel 1 b are separated by a divider plate 30 a, and the reactionvessel 1 b and the reaction vessel 1 c are separated by a divider plate30 b. The reaction vessel 1 a, the reaction vessel 1 b, and the reactionvessel 1 c are mutually communicated via a gas phase portion in thehousing chamber 2.

Furthermore, a stirring blade 10 a which stirs the reaction mixture 9 ain the reaction vessel 1 a is mounted on one face of the divider plate30 a. Similarly, a stirring blade 10 b which stirs the reaction mixture9 b in the reaction vessel 1 b is mounted on one face of the dividerplate 30 b. Note that the stirring blades 10 a and 10 b in the presentembodiment have a structure in which openings are provided on the innerside.

The stirring blades 10 a and 10 b together with the divider plates 30 aand 30 b are all installed on the same rotation shaft 31. The rotationshaft 31 is installed so as to penetrate through the side wall 3 a fromoutside the housing chamber 2 and reach the side wall 3 b. A rotationdrive apparatus 12 which rotates the rotation shaft 31 is installed onthe end of the rotation shaft 31 nearest the side wall 3 a.

Note that the stirring blades may be installed at any position relativeto the divider plates. The divider plates may be on the upstream side orthe downstream side of the stirring blades, or both arrangements may bepresent. The divider plate may be separated from the stirring blade, butthey are preferably adhered and connected as in FIG. 3 because thedivider plate can be thereby fixed and reinforced. Furthermore, thestirring blade and divider plate do not necessarily have to be in pairs,and there may be cases where no stirring blade is present betweenadjacent divider plates. Providing at least one stirring blade aidsprogression of the polymerization reaction and also enables smoothermovement of solids in the reaction mixture. Alternatively, stirringblade may not be provided, thereby enabling a simpler apparatusconfiguration.

The shape of the divider plate is not particularly limited and may beany shape that has a rotating center and partially blocks the verticalcross-section inside the housing chamber 2 while also providingclearance of a certain width or an opening such that adjacent reactionvessels are communicated. For example, when the housing chamber 2 has ahollow round cylindrical shape, the divider plate may have a disc shapeof a radius smaller than the interior space of the housing chamber, asillustrated in FIG. 3. Note that the shape of the divider plate is notlimited thereto, and may be a cage-like rotating object that does nothave a center axis.

The number of divider plates provided on the rotation shaft may be anynumber of one or greater depending on the size of the housing chamber,the type of polymerization reaction, and the like.

When two or more divider plates are provided, they may have the same ordifferent shapes.

The positions of the divider plates may be any position withoutparticular limitation.

On the other hand, the shape of the stirring blade is not particularlylimited, and may be any shape that is provided coaxially with thedivider plate and that stirs the reaction mixture. The stirring blades10 a and 10 b may be mounted on either one face of the divider plates 30a and 30 b, as illustrated in FIG. 3, or on both faces. Alternatively,stirring blades 10 a and 10 b may be mounted on the rotation shaft 31separately from the divider plates.

The liquid phase portions of the reaction vessels 1 a to 1 c aremutually communicated. As a result, the raw materials and solventssupplied to the reaction vessel 1 a move as a reaction mixturesequentially to the reaction vessels 1 b and 1 c while thepolymerization reaction is driven forward.

Furthermore, the gas phase portions of the reaction vessels 1 a to 1 care also mutually communicated. As a result, the pressure of the gasphase inside the housing chamber 2 is uniform. Due to the temperaturedifference inside the apparatus and the like, the vapor componentgenerated during polymerization in each of the reaction vesselssequentially moves in the direction from the reaction vessel 1 c to thereaction vessels 1 b and 1 a via the gas phase portion and aredischarged from the exhaust line 13.

In the PAS continuous production apparatus 300 in the presentembodiment, clearance with a certain width is present between the innerwall of the housing chamber 2 and the outer edges of the divider plates30 a and 30 b. As a result, the gas phase portions of adjacent reactionvessels are communicated with each other and the liquid phases portionsare communicated with each other, and the reaction mixture, gascontaining vapor components, and the like move. Note that openings suchas through holes or slits may be provided in the divider plates insteadof providing clearance, and the reaction vessels may be communicated viathese openings. Alternatively, both clearance and openings may beprovided. Alternatively, the divider plate may have a mesh form having aplurality of narrow through holes.

The clearance width and the size of the openings are not particularlylimited, and may be set as appropriate according to the shape of thecontainers and the shape and number of divider plates, and the like.

Embodiment 4

Next, yet another embodiment of the present invention will be describedin detail.

In the PAS continuous production apparatus according to the presentembodiment, a plurality of reaction vessels are arranged adjacently inthe vertical direction inside a housing chamber. It is configured suchthat mutually adjacent reaction vessels (not illustrated) are separatedby divider plates that are affixed without gaps, and the reactionmixture moves through a connection pipe sequentially from the upperreaction vessel to the lower reaction vessel. Furthermore, the gas phaseportions of the reaction vessels are mutually communicated by acommunicating pipe. As a result, the pressure of the gas phase in thereaction vessels in the housing chamber is substantially equal. Thecommunicating pipe that connects the gas phase portions may be the sameas the connection pipe through which the reaction mixture sequentiallymoves, or it may be a pipe provided separately from the connection pipe.Here, the case where a first reaction vessel and a second reactionvessel are provided in that order from the top in the vertical directionwill be specifically described as an example. The first reaction vesseland the second reaction vessel are communicated via a first connectionpipe, and the pipe wall of the first connection pipe protrudes on thefirst reaction vessel side. The height of the pipe wall of the firstconnection pipe is provided so as to be equal to the maximum liquidsurface level of liquid that can be held by the first reaction vessel.The first connection pipe penetrates through a first divider plate thatseparates the first reaction vessel and the second reaction vessel.

In the PAS continuous production apparatus having such a configuration,when the height of the reaction mixture exceeds the maximum liquidsurface level of the first reaction vessel, the reaction mixture flowsover the pipe wall of the first connection pipe and flows into the firstconnection pipe, and flows into the second reaction vessel via the firstconnection pipe. The reaction mixture can also be sequentially movedwith such a configuration of the PAS continuous production apparatus.

Furthermore, the gas phase portion of the first reaction vessel and thegas phase portion of the second reaction vessel are mutuallycommunicated by a connection pipe or communicating pipe.

Embodiment 5

Next, yet another embodiment of the present invention will be describedin detail.

FIG. 4 is schematic view of a modified example of the configuration of aPAS continuous production apparatus.

To describe the apparatus in reference to FIG. 4, a PAS continuousproduction apparatus 400 includes a first reaction vessel 50, a secondreaction vessel 51, and a third reaction vessel 52. The second reactionvessel 51 is arranged vertically below the first reaction vessel 50, andthe third reaction vessel 52 is arranged vertically below the secondreaction vessel 51.

The first reaction vessel 50 and the second reaction vessel 51 areconnected by a first pipe 65. The second reaction vessel 51 and thethird reaction vessel 52 are connected by a second pipe 67.

The first pipe 65 is provided such that the reaction mixture (notillustrated) in the first reaction vessel 50 moves to the secondreaction vessel 51 via the first pipe 65 when the reaction mixture inthe first reaction vessel 50 exceeds the maximum liquid surface level.

The second pipe 67 is provided such that the reaction mixture (notillustrated) in the second reaction vessel 51 moves to the thirdreaction vessel 52 via the second pipe 67 when the reaction mixture inthe second reaction vessel 51 exceeds the maximum liquid surface level.

Additionally, a ventilation unit 70 is connected to the first to thirdreaction vessels 50 to 52. The first to third reaction vessels 50 to 52are communicated via the gas phase via the ventilation unit 70.

Through such a configuration of the PAS continuous production apparatus400, an effect similar to that of Embodiments 1 and 2 is also obtainedwhen the reaction mixture is moved sequentially utilizing the differencein maximum liquid surface levels of the first reaction vessel 50 andsecond reaction vessel 51. Additionally, according to the PAS continuousproduction apparatus 400, it is unnecessary to provide the partitions asshown in Embodiments 1 and 2 and the divider plates as shown inEmbodiment 3.

Although the PAS continuous production apparatuses in Embodiments 2 to 5differ in configuration from the PAS continuous production apparatus inEmbodiment 1, all share the common point that the gas phase portions ofeach reaction vessel are communicated. For this reason, dehydration canbe performed and the reaction can be driven forward by the samemechanism as the PAS continuous production apparatus in Embodiment 1.Thus, similar to when the PAS continuous production apparatus inEmbodiment 1 is used, PAS can be produced with good space-time yield.

SUMMARY

As described above, a method of producing polyarylene sulfide (PAS)according to one embodiment of the present invention includes asupplying step of supplying an organic polar solvent, a sulfur source,and a dihalo aromatic compound as reaction raw materials to at least oneof a plurality of reaction vessels mutually communicated via a gasphase; a dehydrating step of removing at least a portion of waterpresent in the plurality of reaction vessels; and a polymerizing step ofperforming a polymerization reaction of the sulfur source and the dihaloaromatic compound in the organic polar solvent. The steps are carriedout in parallel and the reaction mixture is sequentially moved betweenthe reaction vessels. The internal temperatures of the plurality ofreaction vessels are all not less than 150° C.

In an embodiment of the present production method, the internaltemperature of the supply reaction vessel into which the reaction rawmaterials are supplied is preferably not less than 170° C. and theinternal temperatures of the reaction vessels other than the supplyreaction vessel are preferably not less than 200° C.

In an embodiment of the present production method, the internaltemperature of the one or more reaction vessels other than the supplyreaction vessel is preferably not less than 245° C.

In an embodiment of the present production method, at least some of theplurality of reaction vessels may be connected in series.

In an embodiment of the present production method, for at least one pairof adjacent reaction vessels among the plurality of reaction vessels,the reaction vessel with a higher maximum liquid surface level of liquidthat can be held in each reaction vessel may be located on the upstreamside of the movement direction of the reaction mixture, and the reactionmixture may be moved utilizing the difference in maximum liquid surfacelevels.

In an embodiment of the present production method, the plurality ofreaction vessels may be connected in descending order of maximum liquidsurface level of liquid that can be held in each reaction vessel fromthe upstream side toward the downstream side of the movement directionof the reaction mixture, and the reaction mixture may be moved utilizingthe difference in maximum liquid surface levels.

In an embodiment of the present production method, a feeding step offeeding an inert gas from the downstream side toward the upstream sideof the movement direction of the reaction mixture may be further carriedout in parallel with each of the steps.

In an embodiment of the present production method, a separating andrecovering step of separating and recovering a portion of the reactionraw materials and a resupplying step of supplying at least a portion ofthe reaction raw materials to one or more of the reaction vessels may befurther carried out in parallel with each of the steps.

In an embodiment of the present production method, the internaltemperatures of the reaction vessels are set so as to increase from theupstream side toward the downstream side of the movement direction ofthe reaction mixture.

In an embodiment of the present production method, the pressure in thereaction system is preferably from 0.01 MPa to 0.8 MPa.

In an embodiment of the present production method, the space-time yieldis preferably not less than 14 g/hr·L.

In an embodiment of the present production method, the total supplyquantity of the sulfur source in terms of sulfur atoms is preferably notless than 0.1 Kmol, and the time from the start of the supplying step tocompletion of the polymerizing step is preferably not greater than 7hours.

In an embodiment of the present production method, the total supplyquantity of the sulfur source in terms of sulfur atoms is preferably notless than 0.1 mol/hr, and the time from the start of the supplying stepto completion of the polymerizing step is preferably not greater than 7hours.

In an embodiment of the present production method, the method furtherincludes a step of increasing the weight average molecular weight ofpolyarylene sulfide obtained by the polymerizing step.

Embodiments of the present invention will be described in further detailhereinafter using examples. The present invention is not limited to theexamples below, and it goes without saying that various aspects arepossible with regard to the details thereof. Furthermore, the presentinvention is not limited to the embodiments described above, and variousmodifications are possible within the scope indicated in the claims.Embodiments obtained by appropriately combining the technical meansdisclosed by the embodiments are also included in the technical scope ofthe present invention. In addition, all of the documents disclosed inthe present specification are hereby incorporated by reference.

EXAMPLES Example 1

Examples of the present invention will be described in further detail.

The same PAS continuous production apparatus as that illustrated in FIG.1 was used except that the housing chamber 2 included six reactionvessels divided with five partitions. This PAS continuous productionapparatus was a reaction apparatus made of Ti (internal volumeapproximately 2.1 L) having dimensions of approximately 100 mm indiameter by approximately 300 mm in length and having semicircularpartitions. In the above PAS continuous production apparatus, after 950g of NMP was charged, the temperature 1 of the portions segmented by thefirst partition and the second partition was maintained at 230° C. andthe temperature 2 of the portions segmented by the third partition andthe fourth partition were maintained at 260° C., and raw materialsincluding a mixture of NMP and p-dichlorobenzene (pDCB) at a flow rateof 3.53 g/min (NMP:pDCB (weight ratio)=988:268) and 36.00 wt. % NaSH ata flow rate of 0.84 g/min were continuously supplied from respectivesupply lines using a constant volume pump for 5 hours. The number ofmoles of sulfur source supplied to the reaction apparatus was 1.62 mol.

At the same time, water was continuously removed from the PAS continuousproduction apparatus using a distillation apparatus connected to the PAScontinuous production apparatus while controlling the pressure to agauge pressure of 0.32 MPa using a pressure regulating valve, andfurther, the pDCB in the removed water was separated in a settling tankand returned to the PAS continuous production apparatus.

Furthermore, the gas from the distillation apparatus was washed with15.84 wt. % NaOH at 1.37 g/min and NMP at 0.50 g/min supplied to a gasabsorption column, and then released. At that time, the total amount ofthe NaOH aqueous solution and NMP in which gas had been absorbed wassupplied from the upstream side to the reaction vessel on the upstreamside of the first partition. As a result, the water supplied from theupstream side to the reaction vessel on the upstream side of the firstpartition was 17.4 mol per mol of sulfur source.

The polymerization reaction product was continuously extracted byallowing it to overflow from the reaction apparatus, and then cooled.

The time until the charged raw materials were recovered as a polymer,specifically, the total time of the charging step, the dehydrating step,and the polymerizing step was 3 hours on average. The space-time yieldwas 16 g/hr·L.

The obtained reaction product was collected and analyzed. The rawmaterial pDCB conversion ratio was 97.0%. The reaction mixture waswashed three times with an equal weight of acetone and three times withan equal weight of water. It was then filtered, and the obtained cakewas dried under vacuum at 80° C. for 8 hours, to obtain PPS powder. Theweight average molecular weight Mw according to GPC of the PPS powderwas 27300.

Example 2

The same PAS continuous production apparatus as that illustrated in FIG.3 was used except that the housing chamber included 11 reaction vesselsdivided with 10 disk-shaped divider plates. In this continuousproduction apparatus, the housing chamber body had dimensions of 108 mmin inner diameter by 300 mm in length. All of the 10 divider plates hadthe same shape, and were provided on a rotation shaft of diameter 5 mm.On the face of each divider plate on the upstream side of the movementdirection of the reaction mixture, two anchor-type stirring blades madeof the same material as the downstream-side divider plate were providedin a plus-sign formation. The diameter of each divider plate was 100 mm,the length in the long axial direction of the anchor-type stirringblades was 90 mm, and the length thereof in the short axial directionwas 40 mm. At the location where the divider plate was provided, theproportion of the cross-section of clearance relative to theperpendicular cross-section of the interior space of the housing chamberwas approximately 14%.

In the above continuous production apparatus, after 1700 g ofN-methyl-2-pyrrolidone (NMP) as an organic amide solvent was charged,the temperature 1 of the second reaction vessel counting from theupstream side was maintained at 230° C., the temperature 2 of the fifthreaction vessel was maintained at 260° C., and the temperature 3 of the11th reaction vessel was maintained at 260° C. using an external heaterinstalled on the bottom portion of the housing chamber while nitrogengas was allowed to flow from the downstream side of the 11th reactionvessel counting from the upstream side of the movement direction of thereaction mixture. Here, the flow rate of nitrogen gas was 0.1 NL/min,and at standard state, the linear flow rate of nitrogen gas passingthrough the clearance of the divider plate was 0.8 cm/s.

Raw materials including an NMP-pDCB mixture at a flow rate of 3.76 g/min(NMP:pDCB (weight ratio)=1852:1382) and 36.5 wt. % NaSH at a flow rateof 1.63 g/min were continuously supplied from respective supply linesusing a constant volume pump.

At the same time, water was continuously removed from the continuousproduction apparatus using a distillation apparatus connected to thecontinuous production apparatus while controlling the pressure to agauge pressure of 0.32 MPa using a pressure regulating valve. Further,the pDCB in the removed water was separated in a settling tank andreturned to the continuous production apparatus. Furthermore, the gasfrom the distillation apparatus was washed with 16.32 wt. % NaOH at 2.68g/min and NMP at 0.50 g/min supplied to a gas absorption column, andthen released. At that time, the total amount of the NaOH aqueoussolution and NMP in which gas had been absorbed was supplied from theupstream side to the first reaction vessel.

After the above operation was continued for 6 hours, the obtainedreaction product was collected and analyzed. The raw material pDCBconversion ratio according to gas chromatography analysis was 93.8% Thereaction mixture was washed three times with an equal weight of acetoneand three times with an equal weight of water and then filtered. Theobtained cake was dried under vacuum at 80° C. for 8 hours, to obtainPPS powder. The weight average molecular weight Mw according to GPC ofthe PPS powder was 11000.

REFERENCE SIGNS LIST

1 a, 1 b, 1 c Reaction vessel

2 Housing chamber

3 a, 3 b Side wall

4 Organic polar solvent supply line

5 Sulfur source supply line

6 Dihalo aromatic compound supply line

7 Reaction mixture recovery line

8 a, 8 b Partition

9 a, 9 b, 9 c Reaction mixture

10 a, 10 b, 10 c Stirring blade

11 Stirring shaft

12 Rotation drive apparatus

13 Exhaust line

14 Dehydrating unit

15 Organic polar solvent recovery line

16 Vapor recovery line

17 Gas-liquid separating unit

18 Gas recovery line

19, 24 Reaction raw material separating and recovering unit

20 Waste gas line

21, 26 Reaction raw material resupply line

22, 27 Reaction raw material resupply unit

23 Liquid recovery line

25 Waste water line

28 Gas feeding unit

29 Gas feeding line

30 a, 30 b Divider plate

31 Rotation shaft

100, 200, 300, 400 PAS continuous production apparatus

H Horizontal plane

1. A method of producing polyarylene sulfide, the method comprising: asupplying step of supplying an organic polar solvent, a sulfur source,and a dihalo aromatic compound as reaction raw materials to at least oneof a plurality of reaction vessels mutually communicated via a gasphase; a dehydrating step of removing at least a portion of waterpresent in the plurality of reaction vessels; and a polymerizing step ofperforming a polymerization reaction of the sulfur source and the dihaloaromatic compound in the organic polar solvent, wherein the steps arecarried out in parallel and a reaction mixture is sequentially movedbetween the reaction vessels; and internal temperatures of the pluralityof reaction vessels are all not less than 150° C.
 2. The method ofproducing polyarylene sulfide according to claim 1, wherein an internaltemperature of a supply reaction vessel into which the reaction rawmaterials are supplied is not less than 170° C. and internaltemperatures of the reaction vessels other than the supply reactionvessel are not less than 200° C.
 3. The method of producing polyarylenesulfide according to claim 2, wherein an internal temperature of one ormore reaction vessels other than the supply reaction vessel is not lessthan 245° C.
 4. The method of producing polyarylene sulfide according toclaim 1, wherein at least some of the plurality of reaction vessels areconnected in series.
 5. The method of producing polyarylene sulfideaccording to claim 1, wherein, for at least one pair of adjacentreaction vessels among the plurality of reaction vessels, a reactionvessel with a higher maximum liquid surface level of liquid that can beheld in each reaction vessel is located on an upstream side in amovement direction of the reaction mixture, and the reaction mixture ismoved utilizing a difference in maximum liquid surface levels.
 6. Themethod of producing polyarylene sulfide according to claim 1, whereinthe plurality of reaction vessels are connected in descending order ofmaximum liquid surface level of liquid that can be held in each reactionvessel from an upstream side toward a downstream side of the movementdirection of the reaction mixture, and the reaction mixture is movedutilizing a difference in maximum liquid surface levels.
 7. The methodof producing polyarylene sulfide according to claim 1, wherein a feedingstep of feeding an inert gas from the downstream side toward theupstream side of the movement direction of the reaction mixture isfurther carried out in parallel with each of the steps.
 8. The method ofproducing polyarylene sulfide according to claim 1, wherein a separatingand recovering step of separating and recovering a portion of thereaction raw materials and a resupplying step of supplying at least aportion of the reaction raw materials to at least one of the reactionvessels are further carried out in parallel with each of the steps. 9.The method of producing polyarylene sulfide according to claim 1,wherein the internal temperatures of the reaction vessels are set so asto increase from the upstream side toward the downstream side of themovement direction of the reaction mixture.
 10. The method of producingpolyarylene sulfide according to claim 1, wherein a pressure in thereaction system is from 0.01 MPa to 0.8 MPa.
 11. The method of producingpolyarylene sulfide according to claim 1, wherein a space-time yield isnot less than 14 g/hr. L.
 12. The method of producing polyarylenesulfide according to claim 1, wherein a total supply quantity of thesulfur source in terms of sulfur atoms is not less than 0.1 Kmol, and atime from a start of the supplying step to completion of thepolymerizing step is not greater than 7 hours.
 13. The method ofproducing polyarylene sulfide according to claim 1, wherein a totalsupply quantity of the sulfur source in terms of sulfur atoms is notless than 0.1 mol/hr, and a time from a start of the supplying step tocompletion of the polymerizing step is not greater than 7 hours.
 14. Themethod of producing polyarylene sulfide according to claim 1, furthercomprising a step of increasing a weight average molecular weight ofpolyarylene sulfide obtained by the polymerizing step.